Deep grip mechanism within blow mold hanger and related methods and bottles

ABSTRACT

Disclosed is a mold hanger for supporting a bottle mold in a blow molding station, the mold hanger comprising a piston and piston sleeve fully contained within the mold hanger configured to push a moveable insert into the mold. Also disclosed is a method of retrofitting an original rotatable blow molding module having multiple existing blow molding stations, each existing mold hanger defining an existing outer envelope. The disclosed method may include providing an improved mold hanger substantially contained within the respective existing outer envelope and including low-profile drive mechanisms configured opposably to drive moveable inserts into the mold. Further disclosed is a method of manufacturing a blow molded bottle with a deep pinch grip, the method including providing within a mold hanger a drive mechanism to drive a moveable insert into the mold. A bottle made by such methods is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.13/841,745, filed on Mar. 15, 2013, the content of which is herebyincorporated by reference in its entirety.

BACKGROUND

The present invention relates generally to blow molding containers, andmore particularly to using moveable inserts to mold a deep-grip bottle,for example.

A prior art arrangement 102 for blow molding containers is shown inFIG. 1. A rotatable blow molding module 110 may have sixteen blowmolding stations 12, for example. This may be a known Sidel-type SB0-16GUPM module. The arrangement may include heating module 104, transfermodule 106, and transfer module 108. The horizontal dimensions of agiven blow molding module 12 define a space envelope 99.

In another prior art arrangement shown in FIG. 12, a rotatable blowmolding module may have ten blow molding stations 12. This may be aknown Sidel-type SB0-10 GUPM module.

In the prior art arrangements, each blow molding station 12 may includea mold 16 supported by a mold hanger 14, as depicted in FIG. 2. The moldmay include cavity 345 for forming bottle 24 with grip 39. The blowmolding station 12 may open in two halves 13. The mold may have a bottom47 that needs to move downward to release bottle 24 at exit station 101depicted in FIG. 12.

SUMMARY

As embodied herein, the present disclosure is directed to methods ofretrofitting an original rotatable blow molding module having multipleexisting blow molding stations affixed to the rotatable blow moldingmodule, each existing blow molding station having an existing moldhanger for supporting and encasing a mold for a bottle, each existingmold hanger defining an existing outer envelope, the method comprising:providing in each blow molding station an improved mold hanger, theimproved mold hanger substantially contained within the respectiveexisting outer envelope and configured to support and encase a mold forblow molding a bottle from plastic; and providing in each improved moldhanger a pair of low-profile drive mechanisms configured to opposablydrive a respective pair of moveable inserts at least one half inch intoa cavity of the mold while the plastic is molten.

As embodied herein, the present disclosure is directed to methods ofmanufacturing a blow molded bottle with a deep pinch grip comprising:providing a mold hanger defining an outer envelope; providing in themold hanger a mold with a cavity configured to receive molten plastic;providing within the outer envelope a first moveable insert; providingwithin the outer envelope a second moveable insert; providing within themold hanger a first drive mechanism configured to drive the firstmoveable insert in a first direction into the cavity; providing withinthe mold hanger a second drive mechanism configured to drive the secondmoveable insert in a second direction into the cavity, the seconddirection being generally opposed to the first direction; blowing moltenplastic into contact with the mold; and after blowing the molten plasticinto contact with the mold, operating the first and second drivemechanisms to drive the first and second moveable inserts into thecavity while the plastic is still pliable and form a blow-molded bottlewith a deep pinch grip, and to blow-molded bottles manufacturedaccording to such methods.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram of a prior art arrangement for blow moldingcontainers.

FIG. 2 is a perspective view of part of a prior art blow moldingstation.

FIG. 3 is a front view of part of an inventive blow molding station atan early stage of operation.

FIG. 4 is a front view of the part of an inventive blow molding stationfrom FIG. 3, shown at a later stage.

FIG. 5 is a cross-sectional view of an inventive mold with moveableinserts at a first stage.

FIG. 6 is a cross-sectional view of the mold of FIG. 5 shown at a secondstage.

FIG. 7 is a cross-sectional view of the mold of FIG. 5 shown at a thirdstage.

FIG. 8 is a cross-sectional view of the mold of FIG. 5 shown at a fourthstage.

FIG. 9 is a cross-sectional view of the mold of FIG. 5 shown at a fifthstage.

FIG. 10 is a perspective view of an inventive mold hanger.

FIG. 11 is a top down view of an inventive mold hanger, piston, andmold.

FIG. 12 is a diagram of a prior art module with blow molding stationsfor blow molding containers.

FIG. 13 is a composite front view of an inventive blow molding stationshown at two different times.

FIG. 14 is a top down plan of the composite view shown in FIG. 13.

DETAILED DESCRIPTION

Under a cooperative research and development agreement, it has beensuggested to the present inventors to provide moveable inserts or slidesin a mold to provide a grip deeper than the grip 39 provided by theconventional arrangement shown in FIG. 2. The moveable inserts wouldmove into the mold toward the end of the blowing process, but while theplastic was still malleable. The inventors have recognized thatproviding for moveable inserts in a low profile manner will permit themoveable inserts to be used in a conventional rotatable blow moldingmodule where space is limited. This preserves a favorable productionrate and efficiency of existing arrangements, such as the ten stationrotatable blow molding module depicted in FIG. 12 and the sixteenstation rotatable blow molding module 110 depicted in FIG. 1. Providingand actuating moveable inserts in the low profile manner as describedherein obviates the need to use fewer stations on a given rotatable blowmolding module or the need to increase the size of the rotatable blowmolding module which would otherwise be necessary if lateral spaceenvelope 99 of each blow molding station were significantly enlarged.

In a conventional ten station rotatable blow molding module as depictedin FIG. 12, finished bottle 24 is ejected at an ejection station 101having a certain clearance 130 between an open mold hanger 314 in oneexisting blow molding station 12 and an open mold hanger 414 in anidentical adjacent existing blow molding station 12. The outer envelope99 of each mold hanger 314 and 414 of each existing blow molding station12 cannot be increased by more than the clearance distance 130. In otherwords, the increase in lateral direction 103 and the increase in lateraldirection 105 cannot together total more than clearance distance 130.Otherwise, mold hangers 314 and 414 would collide when they are openedat the ejection station. Preferably, the total increase of outerenvelope 99 is significantly less than clearance distance 130. Thisallows for clearance distance 130 to be at least as large as a desiredsafety margin allowing for machining tolerances, positioning tolerances,hoses possibly getting positioned between adjacent hangers, and othersafety considerations.

For a typical Sidel-type ten station rotatable blow molding module, e.g.Sidel SB0-10 GUPM, clearance 130 may be 66 millimeters. In that case,the desired safety margin may be 25 millimeters, permitting the totalincrease of outer envelope to be equal to, or preferably less than, 41millimeters. All of the various inventive mechanisms described hereincan easily be installed in each blow molding station while adding nomore than 26 millimeters to the outer envelope 99. With furtherrefinements, such as for example using stronger (and therefore thinner)metal in the mold hanger, the inventive drive mechanisms describedherein may be added to an existing blow molding station 12 withoutcausing the improved blow molding station to extend laterally beyondouter envelope 99.

Use of moveable inserts at various stages of a blow molding process isdepicted in FIGS. 5 through 9.

FIG. 5 is a cross-section of a mold at a first stage. Here, preform 124is shown centered on axis 194 of cavity 345 in mold 116. Moveableinserts 118 and 120 are shown in their outward or fully retractedposition. Moveable insert 118 is slideably engaged in moveable insertpocket 122.

FIG. 6 is a cross-sectional view of the mold of FIG. 5 shown at a secondstage. By this time, preform 124 has been blown somewhat outward tointermediate form 224.

FIG. 7 is a cross-sectional view of the mold of FIG. 5 shown at a thirdstage. By this time, intermediate form 224 has expanded to pre-shape 324in partial contact with cavity 345.

FIG. 8 is a cross-sectional view of the mold of FIG. 5 shown at a fourthstage. By this time, pre-shape 324 has expanded to initial shape 424 insubstantially full contact with cavity 345. Such contact may causeinitial shape 424 to start cooling and hardening slightly.

FIG. 9 is a cross-sectional view of the mold of FIG. 5 shown at a fifthstage. Shortly after the stage shown in FIG. 8, moveable inserts 118 and120 will advance into cavity 345 before initial shape 424 significantlyhardens. Moveable inserts 118 and 120 are shown in FIG. 9 having movedto their inward or fully engaged position. The movement of moveableinserts 118 form their outward position to their inward position whilethe plastic is still molten moves the shallow grip in initial shape 424into a deep pinch grip 539 to form deep pinch grip bottle 524.

Deep pinch grip 539 has a width 525 smaller than a width that would bepossible in these circumstances without moveable inserts. It isdifficult and costly to attempt to blow mold such a deep pinch gripbottle without using slides. Deep pinch grip 539 provides larger ledges526 and 526 to rest on fingers and a thumb of a user. For example,ledges 526 and 528 may each have a depth indicated at dimension 527.Dimension 527 may be at least 29 milimeters, providing a secure ledgefor pinch grip 539. Use of the moveable inserts can increase the depthof the ledges from 16 millimeters to 29 millimeters and decrease thewidth 525 of the grip from 3 and ⅛ inch to 2⅛ inch in a 1.75 literbottle, for example. This is especially beneficial in a large heavybottle, such as a 1.75 liter liquor bottle. Deep pinch grip 539 providesstability in an energy- and plastic-efficient design.

The inventors have devised several ways of adding moveable inserts to ablow molding station in a manner having a profile low enough to permituse of an otherwise standard blow molding module. In one embodiment, themoveable inserts are moved by a low-profile piston preferably containedin a mold hanger. In another embodiment, the moveable inserts are movedby a low-profile cam preferably contained in a mold. A low-profilepiston and a low-profile cam are both means for driving moveableinserts.

FIG. 3 is a front view of part of an inventive blow molding station 112with mold hanger 114 and mold 116, at an early stage of operation.Initial shape 424 is still molten and moveable inserts 118 and 120 arejust about to start travelling inward from the outward position shown inFIG. 3. Piston 166 is provided in piston sleeve 159. In this figure,piston top 165 of piston 166 is adjacent piston sleeve head end 164.Piston 166 is ready to start pushing moveable insert 118 inward throughinsert pocket 122, by piston 166 advancing in piston sleeve 159 intoannular space 123.

FIG. 4 is a front view of the part of an inventive blow molding stationfrom FIG. 3, shown at a later stage. Initial shape 424 has been pushedinward by inserts 118 and 120, to form bottle 524. The movement ofpiston 166 has filled annular space 123 and vacated annular space 119.That motion has pushed inserts 118 through insert pocket 122.

At the stage shown in FIG. 4, piston top 165 has advanced beyondoptional latches 181 and 183. Latches 181 and 183 may be moved fromoutside piston sleeve 159 to protrude into annular space 119 by fluidpressure or spring force, for example. By thus protruding, latches 181and 183 resist movement of piston 166 in the outward direction. Suchengagement of latches 181 and 183 can ensure moveable insert 118 staysin place in its inward position even if air pressure blowing outwardfrom center line 193 applies outward pressure to moveable insert 118.Latches 181 and 183 may remain engaged until bottle 524 has hardenedsufficiently to move piston 166 back to its outward position wherepiston top 165 is adjacent piston sleeve head end 164. At that time,latches 181 and 183 may be disengaged by application or release ofspring or fluid pressure, for example.

FIG. 10 is a perspective view of an inventive mold hanger. Piston sleeve159 meets piston sleeve head end 164 in mold hanger 114. Piston sleevehead end 164 has first source of fluid pressure 162 centered therein.Mold hanger 114 has hinge 150 to be rotatably secured to the back ofblow molding station 112 and clasp 152 to close the front of blowmolding station 112 during blow molding. Mold hanger 114 may becharacterized by vertical direction 189 and horizontal direction 187.

FIG. 11 is a top down view of an inventive mold hanger, piston, andmold. Piston 166 rides in piston sleeve 122, secured by annular seal182. Piston 166 drives moveable insert 118 in insert picket 122, guidedby guides 190 cooperating with bushings (not shown). Duct 170 may have afemale pipe thread and brings fluid pressure through high pressure fluidinlet hole 168 to first source of fluid pressure 162. Duct 170preferably travels down within hanger 114 to obtain fluid pressure fromthe bottom of blow molding station 112. Alternately, duct 170 mayconnect to a feed hose supplying fluid pressure. Fluid pressure formfirst source of fluid pressure 162 presses against piston top 165 tourge piston 166 inwardly in piston sleeve 159 which in turn pushesmoveable insert 118 inwardly in moveable insert pocket 122. The fluid inmoveable insert pocket 122 may be exhausted to feed hole 178 via passage177 in mold hanger 114. Feed hole 178 is preferably a low pressure airreturn line which originates at the bottom of mold hanger 114.

Once piston 166 and moveable insert 118 are in their inward position,they form deep pinch grip 539 as previously described. When deep pinchgrip bottle 524 is sufficiently hardneded, moveable insert 118 can bemoved in back to its outward position, forcing piston top 165 out to itsoutward position adjacent piston sleeve head end 164. This backwardmovement can be accomplished by applying fluid pressure against thebottom 184 of piston 166, such as by introducing fluid pressure fromsecond source of fluid pressure 174 supplied by duct 187 through passage177.

In FIG. 11, optional latches 181 and 183 are shown in their disengagedposition.

FIG. 12 is a diagram of a prior art module with blow molding stationsfor blow molding containers.

FIG. 13 is a composite front view of an inventive blow molding stationshown at two different times. Mold 216 is secured by mold hanger 214 andcontains moveable insert 118. Moveable insert 118 is completelycontained within mold 216. As shown in the right half of FIG. 13,moveable insert 120 is in its outward position. Fluid actuation cylinder19 is prepared to push cylinder 161 up through path 171 to force camfollower 15 from position 5 to position 1 along path 4. Because thegroove 3 cam follower 15 rides in is angled outwardly and upwardly, theforce of cam follower 15 being forced from position 5 to position 1pushes moveable insert 120 inwardly under the force of the inclinedplane along dogleg path 2.

The inward position is shown at a later time in the left half of FIG.13. There, the cam follower is in the up position 6, holding moveableinsert 118 in its inward position to form a deep grip pinch in bottle624. When bottle 624 is sufficiently cooled and hardened in mold cavity126, moveable insert 118 can be moved to the outward position by fluidactuation cylinder 919 operating in reverse. That is, fluid actuationcylinder 919 pulls the cam follower from position 6 to position 9 alongdogleg path 7 in groove 8. Because groove 8 is angled downwardly andinwardly, pulling the cam follower down from position 6 to position 9applies an inclined plane force pulling moveable insert 118 outward awayfrom bottle 624 and out of cavity 126.

Thus, drive mechanism 312 comprises a cam follower or roller in groove 8and cylinder shaft 313, all contained in mold 216.

FIG. 14 is a top down plan of the composite view shown in FIG. 13. Inthe bottom half, moveable element 218 is in the inward position. In thetop half, moveable element is shown being retracted from the inwardposition shown in the bottom half, at a later time than that depicted inthe bottom half. Cylinder linkage 12 is shown linking cylinder 161 withcam follower 15 via shaft 13 holding cam follower 15 and cam follower715.

In one exemplary embodiment, the invention comprises a mold hanger 114for supporting a bottle mold 116 in a blow molding station 112, the moldhanger 114 having a vertical direction 189 and a horizontal direction187, the mold hanger 114 comprising a piston sleeve 159 fully containedwithin the mold hanger 114 and orthogonal to both the vertical direction189 and the horizontal direction 187; a piston sleeve head end 164capping the piston sleeve 159; a piston 166 slideably engaged with andfully contained within the piston sleeve 159, the piston 166 having apiston top 165 conforming to the size and shape of the piston sleevehead end 164 and a piston bottom 184; a moveable insert 118 integralwith the piston bottom 184 and configured to be pushed by the pistonbottom 184 in an inward direction away from the piston sleeve head end164 into a mold 116 supported by the mold hanger 114; and a first sourceof fluid pressure 162 configured to apply pressure to the piston top 165to push the piston 166 slideably away from the piston sleeve head end164 and toward the mold 116; wherein the piston top 165 has an arealarger than a cross sectional area of the moveable insert 118.

The mold hanger 114 may have a second source of fluid pressure 174configured to apply pressure to the piston bottom 184 to push the piston186 slideably toward the piston sleeve head end 164.

The first source of fluid pressure 162 preferably provides pressurizedair from a pressurized air source that is also used to blow mold abottle 24 in the bottle mold. Alternatively, the first source of fluidpressure 162 may provide hydraulic pressure.

Preferably, fluid pressure from the first source of fluid pressure 162is sufficient to hold piston 166 and moveable insert 118 in the inwardposition shown in FIGS. 3 and 9 against outward pressure frompressurized air used to mold the bottle. However, latches 181 and 183may be provided to hold piston 166 and moveable insert 118 in thatinward position. Latches 181 and 183 may contain springs and/or may beactuated by fluid pressure available in mold hanger 114.

A central axis 192 of piston 166 may be parallel to and laterallydisplaced from a central axis 194 of moveable insert 118. This lateraloffset may provide room for second source of fluid pressure 174 tocommunicate with fluid passage 178 in mold hanger 114. The lateraloffset may permit piston 166 to be centered along the horizontaldirection 187 of mold hanger 114 while moveable insert 118 is off centerto provide deep grip 539 offset from the center of the bottle which maybe at axis 192.

Moveable insert 118 of mold hanger 114 may be configured to be pushed atleast about one half inch into mold 116 supported by mold hanger 114.With such inserts in both halves of mold 116, deep grip 539 may be atleast one inch deeper than without the insert. This may permit ledges526 and 528 each to have a depth 527 of at least 29 millimeters insteadof only about 16 millimeters without the moveable insert.

Piston sleeve 159 may be no more than one inch long in its axialdirection along its axis 194. This length accommodates both the traveldistance of piston 166 and the thickness of piston 166 itself. Forexample, if piston 166 is one half inch thick, piston 166 may travel onehalf inch within a one inch piston sleeve 159. If piston 166 were onequarter inch thick, piston 166 could travel three quarters of an inchwithin a one inch piston sleeve 159.

With the low profile of a once inch piston sleeve 159, mold hanger 114may be no more than about two inches thick in the portion 675surrounding piston sleeve 159. Mold hanger 114 may be no more than aboutone inch thick in the portion 677 beyond the piston sleeve head end 164.The thickness of mold hanger 114 could be reduced further by use ofstronger metal, such as titanium. The thickness of a standard existingSidel mold hanger is shown in FIG. 11 by phantom line 172. As can beseen, the added thickness at portion 675 and 677 is minimal.

In a second exemplary embodiment, there is provided a method ofretrofitting an original rotatable blow molding module 110 havingmultiple existing blow molding stations 112 affixed to the rotatableblow molding module 110, each existing blow molding station 112 havingan existing mold hanger 14 for supporting and encasing mold 16 for abottle 24, each existing mold hanger 14 defining an existing outerenvelope 99, the method comprising: providing in each blow moldingstation 112 an improved mold hanger, the improved mold hangersubstantially contained within the respective existing outer envelope 99and configured to support and encase a mold for blow molding a bottle524 from plastic; and providing in each improved mold hanger a pair oflow-profile drive mechanisms configured opposably to drive a respectivepair of moveable inserts 118 and 120 at least one half inch into acavity of the mold 116 while the plastic is molten.

The method may further comprise providing a fluid pressure source influid communication with the drive mechanisms. The fluid pressure sourcemay provide pneumatic or hydraulic pressure and may include pressureduct 170, for example. The method may include redirecting fluid pressurepre-existing on each existing blow molding station 112. In that case,pressure duct 170 may receive pressure from the same source of pressureused to blow mold containers in the mold, for example.

Alternately the fluid pressure source used in the method may comprise orbe in fluid communication with a low profile, high pressure, canister19. The method may include securing low profile, high pressure, canister19 in each blow molding station below the respective mold in fluidcommunication with the respective drive mechanisms.

In the method, providing an improved mold hanger may comprises replacingthe existing mold hanger 14. Or it may comprise reusing the existingmold hanger in altered form.

The method may include providing a drive mechanism comprising a slottedcam or a piston, for example. In the case of a piston, the piston mayhave a cross-sectional area larger than a cross-sectional area of themoveable insert. In this manner, the cross-sectional surface area of thepiston that is impacted by fluid pressure pushing the piston in towardthe mold is greater than the cross-sectional area of moveable insertsubject to outward pressure from the air pressure used to blow mold abottle in the mold. This helps ensure that the force of the drivemechanism pushing the moveable insert into the mold is strong enough toovercome friction and outward pressure even if the fluid pressure usedto blow mold the bottle is the same as or less than the fluid pressureused to drive the drive mechanism inward.

In the method, the drive mechanism may be configured to drive themoveable insert within an insert pocket in the mold.

The method may be used where the original rotatable blow molding modulebefore the retrofitting has no more than about 66 millimeters clearancebetween respective existing blow molding stations in operation. Therotatable blow molding module may be a ten-station Sidel-type GUPMwheel, for example. Before the retrofitting, the original rotatable blowmolding module may have no moveable mold inserts.

In the method the moveable insert may be configured to move at leastabout one half inch into an interior cavity inside the mold.

A third exemplary embodiment provides a method of manufacturing a blowmolded bottle 524 with a deep pinch grip 539 comprising: providing amold hanger defining an outer envelope; providing in the mold banger amold with a cavity 345 configured to receive molten plastic; providingwithin the outer envelope a first moveable insert 118; providing withinthe outer envelope a second moveable insert 120; providing within themold hanger a first drive mechanism configured to drive the firstmoveable insert 118 in a first direction into the cavity 345; providingwithin the mold hanger a second drive mechanism configured to drive thesecond moveable insert 120 in a second direction into the cavity 345,the second direction being generally opposed to the first direction;blowing molten plastic into contact with the mold; and after blowing themolten plastic into contact with the mold, operating the first andsecond drive mechanisms to drive the first and second moveable insertsinto the cavity 345 while the plastic is still pliable and form ablow-molded bottle 534 with a deep pinch grip 539.

The method may include operating the first and second drive mechanismsto drive the first moveable insert 118 at least about one half inch intothe cavity 345 and to drive the second moveable insert 120 at leastabout one half inch into the cavity 345.

In this method, deep pinch grip 539 may have a first ledge 526 at leastabout 29 millimeters deep formed by the first moveable insert 118 and asecond ledge at least about 29 millimeters deep formed by the secondmoveable insert 120, as depicted in FIG. 9. Deep pinch grip 539 may havea width 525 equal to or less than about 2⅛ inches, for example.

The exemplary method of manufacturing a blow molded bottle 524 with adeep pinch grip 539 may further comprise operating the first and seconddrive mechanisms in reverse to move the first and second moveableinserts away from the blow-molded bottle.

A fourth exemplary embodiment is a blow molded bottle 524 with a deeppinch grip 539 manufactured according to a method described above in thethird exemplary embodiment. Such a bottle may be, for example, a 1.75litre bottle with a deep pinch grip 539 no more than about 2⅛ inch wide(shown as dimension 525 in FIG. 9) and having a ledge 526 at least about29 millimeters deep on a first side of the grip and a ledge 528 at leastabout 29 millimeters deep on a second side of the grip (shown asdimension 527 in FIG. 9).

In a fifth exemplary embodiment, the invention provides a mold with acavity for forming a deep grip container, the mold comprising: a firstmold pocket configured to receive a first moveable insert; a second moldpocket configured to receive a second moveable insert; a first drivemechanism fully contained within the mold and configured to drive thefirst moveable insert in a first direction through the first mold pocketinto the cavity; and a second drive mechanism fully contained within themold and configured to drive the second moveable insert in a seconddirection through the second mold pocket into the cavity, the seconddirection being generally opposed to the first direction.

The first drive mechanism may include a slotted cam. The mold mayfurther comprise a cylinder shaft positioned in a cylinder shaft hole inthe mold, the cylinder shaft in mechanical cooperation with the firstdrive mechanism. Such a mold may also have a linkage between thecylinder shaft and the first drive mechanism. It may further have anangled roller slot in the mold, angled upward and outward in relation tothe cavity and a roller mounted to the linkage and adapted to roll inthe roller slot. The angled roller slot may be a dog leg configurationwith a straight portion of the slot located above an angled portion. Thecylinder shaft can be configured to be operated by a fluid pressurecylinder mounted to a bottom surface of the mold. The fluid pressurecylinder may operate under hydraulic or pneumatic pressure.

In the mold of the fifth exemplary embodiment, the first drive mechanismmay be configured to drive the first moveable insert in the firstdirection at least one half inch into the cavity and the second drivemechanism may be configured to drive the second moveable insert in thesecond direction at least one half inch into the cavity.

In a sixth exemplary embodiment, there is provided a method ofretrofitting an existing blow molding station 12 having an existing moldhanger 14 for supporting and encasing a mold 16 for a bottle 24, theexisting mold hanger defining an existing outer envelope 99. The methodmay comprise providing in the blow molding station an improved moldhanger, the improved mold hanger substantially contained within theexisting outer envelope 99 defined by the existing mold hanger 14 andconfigured to support and encase a mold 116 for blow molding a bottle524 from plastic; and providing in the improved mold hanger a pair oflow-profile drive mechanisms configured to opposably drive a respectivepair of moveable inserts 118 and 120 at least one half inch into acavity 345 of the mold 116 while the plastic is molten.

This method may further include providing a fluid pressure source influid communication with the drive mechanisms. The fluid pressure sourcemay be configured to provide hydraulic pressure or pneumatic pressureand, on one hand, may include fluid pressure pre-existing on andredirected from the existing blow molding station.

On the other hand, the fluid pressure source may be provided by a lowprofile, high pressure, canister. The canister may be secured below themold in fluid communication with the drive mechanisms.

In the sixth exemplary embodiment, providing an improved mold hanger mayinclude replacing the existing mold hanger, reusing the existing moldhanger in altered form, or reusing the existing mold hanger. Providingin the improved mold hanger a pair of low-profile drive mechanisms mayinclude providing the drive mechanisms in a mold supported by theexisting mold hanger.

In the method of retrofitting an existing blow molding station, theimproved mold hanger laterally extends beyond the existing outerenvelope by a cumulative total of less than the clearance distance 130,e.g. 66 millimeters. To include a safety margin, the improved moldhanger laterally extends beyond the existing outer envelope by acumulative total of less than 41 millimeters. In the disclosed method,the improved mold hanger can easily be arranged to extends laterallybeyond the existing outer envelope by a cumulative total of less than 26millimeters. By making certain adjustments, the improved mold hangerwill not extend laterally beyond the existing outer envelope 99 at all.

The drive mechanism in this method may be configured to drive themoveable insert within an insert pocket in the mold. The moveable insertmay be configured to slide within the insert pocket at least about onehalf inch into an interior cavity inside the mold.

In this method the existing blow molding station 12 may be part of aten-station Sidel-type GUPM wheel indicated in FIG. 12 or asixteen-station Sidel-type GUPM wheel indicated in FIG. 1, for example.

In this exemplary method, the drive mechanism may comprise a slotted camor a piston, for example. In the case of a piston, the top surface 165of the piston may have a cross-sectional area larger than across-sectional area of the moveable insert.

In a seventh exemplary embodiment, there is provided a method ofmanufacturing a blow molded bottle with a deep pinch grip comprising:providing a mold hanger having an outer envelope; providing in the moldhanger a mold with a cavity configured to receive molten plastic;providing within the outer envelope a first pocket configured to receivea first moveable insert; providing within the outer envelope a secondpocket configured to receive a second moveable insert; providing withinthe outer envelope a first drive mechanism configured to drive the firstmoveable insert in a first direction through the first pocket into thecavity; providing within the outer envelope a second drive mechanismconfigured to drive the second moveable insert in a second directionthrough the second mold pocket into the cavity, the second directionbeing generally opposed to the first direction; blowing molten plasticinto contact with the mold; and after blowing the molten plastic intocontact with the mold, operating the first and second drive mechanismsto drive the first and second moveable inserts into the cavity while theplastic is still pliable and form a blow-molded bottle with a deep pinchgrip.

This exemplary method may further include operating the first and seconddrive mechanisms in reverse to move the first and second moveableinserts away from the blow-molded bottle.

An eighth exemplary embodiment is a blow molded bottle with a deep pinchgrip manufactured according to the method of the seventh exemplaryembodiment. This bottle may be a 1.75 litre bottle with a deep pinchgrip no more than about 2⅛ inch wide and having a ledge at least about29 millimeters deep on a first side of the grip and a ledge at leastabout 29 millimeters deep on a second side of the grip. Any of thebottles mentioned herein may desirably be a 1.75 litre liquor bottle.

1-10. (canceled)
 11. A method of retrofitting an original rotatable blowmolding module having multiple existing blow molding stations affixed tothe rotatable blow molding module, each existing blow molding stationhaving an existing mold hanger for supporting and encasing a mold for abottle, each existing mold hanger defining an existing outer envelope,the method comprising: providing in each blow molding station animproved mold hanger, the improved mold hanger substantially containedwithin the respective existing outer envelope and configured to supportand encase a mold for blow molding a bottle from plastic; and providingin each improved mold hanger a pair of low-profile drive mechanismsconfigured to opposably drive a respective pair of moveable inserts atleast one half inch into a cavity of the mold while the plastic ismolten.
 12. The method of claim 1, further comprising providing a fluidpressure source in fluid communication with the drive mechanisms. 13.The method of claim 2, wherein the fluid pressure source is configuredto provide hydraulic pressure.
 14. The method of claim 2, wherein thefluid pressure source is configured to provide pneumatic pressure. 15.The method of claim 2, wherein the fluid pressure source comprises a lowprofile, high pressure, canister.
 16. The method of claim 5, whereinproviding a fluid pressure source comprises securing a low profile, highpressure, canister in each blow molding station below the respectivemold in fluid communication with the respective drive mechanisms. 17.The method of claim 2, wherein providing the fluid pressure sourcecomprises redirecting fluid pressure pre-existing on each existing blowmolding station.
 18. The method of claim 1, wherein providing animproved mold hanger comprises replacing the existing mold hanger. 19.The method of claim 1, wherein providing an improved mold hangercomprises reusing the existing mold hanger in altered form.
 20. Themethod of claim 1, wherein each improved mold hanger laterally extendsbeyond the respective existing outer envelope by a cumulative total ofless than 66 millimeters.
 21. The method of claim 1, wherein eachimproved mold hanger laterally extends beyond the respective existingouter envelope by a cumulative total of less than 41 millimeters. 22.The method of claim 1, wherein each improved mold hanger laterallyextends beyond the respective existing outer envelope by a cumulativetotal of less than 26 millimeters.
 23. The method of claim 1, whereineach improved mold hanger does not extend laterally beyond therespective existing outer envelope.
 24. The method of claim 1, whereinthe drive mechanism comprises a slotted cam.
 25. The method of claim 1wherein the drive mechanism comprises a piston.
 26. The method of claim15, wherein the piston has a cross-sectional area larger than across-sectional area of the moveable insert.
 27. The method of claim 1,wherein the drive mechanism is configured to drive the moveable insertwithin an insert pocket in the mold.
 28. The method of claim 1, whereinthe original rotatable blow molding module before the retrofitting hasless than about 66 millimeters clearance between respective existingblow molding stations in operation.
 29. The method of claim 1 whereinthe moveable insert is configured to move at least about one half inchinto an interior cavity inside the mold.
 30. The method of claim 1,wherein the rotatable blow molding module is a ten-station Sidel-typeGUPM wheel.
 31. The method of claim 1, wherein the rotatable blowmolding module is a sixteen-station Sidel-type GUPM wheel.
 32. Themethod of claim 1, wherein the original rotatable blow molding modulebefore the retrofitting has no moveable mold inserts.
 33. A method ofmanufacturing a blow molded bottle with a deep pinch grip comprising:providing a mold hanger defining an outer envelope; providing in themold hanger a mold with a cavity configured to receive molten plastic;providing within the outer envelope a first moveable insert; providingwithin the outer envelope a second moveable insert; providing within themold hanger a first drive mechanism configured to drive the firstmoveable insert in a first direction into the cavity; providing withinthe mold hanger a second drive mechanism configured to drive the secondmoveable insert in a second direction into the cavity, the seconddirection being generally opposed to the first direction; blowing moltenplastic into contact with the mold; and after blowing the molten plasticinto contact with the mold, operating the first and second drivemechanisms to drive the first and second moveable inserts into thecavity while the plastic is still pliable and form a blow-molded bottlewith a deep pinch grip.
 34. The method of claim 23, wherein operatingthe first and second drive mechanisms comprises: driving the firstmoveable insert at least about one half inch into the cavity; anddriving the second moveable insert at least about one half inch into thecavity.
 35. The method of claim 23, wherein the deep pinch grip has afirst ledge at least about 29 millimeters deep formed by the firstmoveable insert and a second ledge at least about 29 millimeters deepformed by the second moveable insert.
 36. The method of claim 23,wherein the bottle is large enough to contain at least about 1.75 litresof liquid.
 37. The method of claim 26, wherein the grip is no more thanabout 2⅛ inch wide.
 38. The method of claim 23, further comprisingoperating the first and second drive mechanisms in reverse to move thefirst and second moveable inserts away from the blow-molded bottle.39-40. (canceled)